Belt weigher weighing system applying digital hydraulic automatic deviation correcting device

Abstract

The invention discloses a belt weigher weighing system applying a digital hydraulic automatic deviation correcting device, and belongs to the technical field of belt weigher weighing. The front end and the rear end of the belt scale body are respectively provided with a digital hydraulic automatic deviation correcting device. Comprising a detection driving wheel, an oil pump, a composite oil cylinder, a dynamic carrier roller, a fixed rack, a fixed bracket and a digital pressure gauge, the fixed rack is used for providing support for the digital hydraulic automatic deviation rectifying device; the fixing support is used for fixing the detection driving wheel and the composite oil cylinder. The detection driving wheel is used for detecting the deviation condition of the belt; the detection driving wheel is used for driving the oil pump to work; the oil pump is used for providing pressure oil for the composite oil cylinder; the composite oil cylinder is used for adjusting the angle of the dynamic carrier roller; the dynamic carrier roller is fixed on the fixed rack through a rotatable flange and is used for supporting and adjusting the belt; the digital pressure gauge is connected with the composite oil cylinder and is used for detecting deviation data; the digital pressure gauge is connected with an instrument of the belt weigher and is used for data transmission. The deviation rectifying action is judged through the pressure value, and the pressure change trend is monitored.

Description

Technical Field

[0001] This invention belongs to the field of belt scale weighing technology, specifically relating to a belt scale weighing system that uses a digital hydraulic automatic correction device. Background Technology

[0002] Belt misalignment is a common problem in belt conveyor and weighing operations. Belt misalignment causes material to shift in position, resulting in uneven material distribution within the weighing area and affecting the accuracy of weighing data. Furthermore, long-term misalignment accelerates belt wear, increases the risk of equipment failure, and reduces conveying and weighing efficiency. Traditional manual correction methods are slow and inaccurate, failing to meet the stability and reliability requirements of modern belt scales. Moreover, even with automatic correction devices, some misaligned sections of the belt may not be fully corrected as they pass through the weighing area, leading to significant left-right pressure deviations and further affecting weighing accuracy. Therefore, a technical solution combining pressure monitoring and off-center load compensation is urgently needed. Summary of the Invention

[0003] This invention aims to address the shortcomings of existing technologies by resolving issues such as inaccurate weighing and equipment wear caused by belt misalignment in belt scale weighing systems. By adding digital hydraulic automatic belt alignment devices before and after the belt scale body, automatic and precise belt alignment is achieved, creating and maintaining an optimal weighing environment for the system. Furthermore, for belt misalignment that is not corrected when passing through the weighing area, off-center load compensation is performed based on real-time pressure monitoring, further improving weighing accuracy and equipment operational stability.

[0004] Based on the above objectives, the present invention proposes the following technical solution: a belt scale weighing system using a digital hydraulic automatic correction device, wherein the belt scale body is equipped with a digital hydraulic automatic correction device at both the front and rear ends; the digital hydraulic automatic correction device includes: a detection drive wheel, an oil pump, a composite oil cylinder, a fixed frame, a fixed bracket, and a digital pressure gauge;

[0005] The fixed frame is connected to the frame of the belt scale and provides support for the digital hydraulic automatic correction device; the fixed bracket is used to fix the inspection drive wheel and the composite cylinder.

[0006] More preferably, the detection wheel contacts the belt to detect belt misalignment;

[0007] The inspection and drive wheel is connected to the oil pump and is used to drive the oil pump to work;

[0008] The oil pump is connected to the composite cylinder via an oil pipe and is used to provide pressurized oil to the composite cylinder.

[0009] The composite hydraulic cylinder is connected to the dynamic idler roller and is used to adjust the angle of the dynamic idler roller;

[0010] The dynamic idler roller is fixed to the fixed frame by a rotatable flange and is used to support and adjust the belt;

[0011] The digital pressure gauge is connected to the composite cylinder and is used to detect deviation data;

[0012] The digital pressure gauge is connected to the belt scale's instrument via an RS485 bus for data transmission.

[0013] More preferably, the belt scale's instrument has a built-in off-center load compensation module;

[0014] The off-center load compensation module establishes a data connection with the weighing sensors of the digital pressure gauge and the belt scale to receive pressure data and initial weighing data, perform off-center load compensation calculations according to a preset algorithm, and output the compensated weighing data.

[0015] More preferably, when the digital pressure gauge detects that the left and right pressure deviation of the composite cylinder exceeds the threshold, and the belt misalignment is not corrected when passing through the weighing area, the off-center load compensation module is activated.

[0016] More preferably, the method for determining if the left-right pressure deviation exceeds the threshold is as follows:

[0017]

[0018] in,

[0019]

[0020] In the formula, T represents the time window; P L (t) represents the time series of pressure in the left hydraulic cylinder; P R (t) represents the time series of pressure in the right cylinder.

[0021] More preferably, the method for calculating the compensated weighing data includes:

[0022] Wc=αP+βΔP+γWr+δ;

[0023] In the formula, Wc represents the weighing compensation result; α represents the degree of influence of the deviation pressure P on the weighing compensation; β represents the degree of influence of the pressure difference ΔP on the weighing compensation; γ represents the influence of the original weighing Wr on the compensation result; δ is a constant bias, representing the basic compensation value under the condition of no pressure or deviation.

[0024] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0025] Improving weighing accuracy: By promptly correcting belt misalignment, the system ensures that materials are evenly distributed within the weighing area, reducing weighing errors caused by belt misalignment. Simultaneously, off-center load compensation is applied to any uncorrected belt misalignment to further eliminate the impact of off-center loading on the weighing results, providing accurate weighing data for the weighing system.

[0026] Automated operation: The entire correction process requires no manual intervention. Components such as the drive wheel, oil pump, and composite cylinder work together to automatically complete a series of operations such as detection, driving, and adjustment. Off-center load compensation is also automatically completed by the instrument, saving labor costs.

[0027] Ensuring equipment safety: Real-time monitoring of the belt alignment device's operating status, determining alignment actions based on pressure values, and monitoring pressure change trends. When abnormalities such as excessive pressure, pressure imbalance, or frequent alignment occur, timely detection and warnings are provided to prevent long-term belt misalignment from damaging the belt and other equipment, thus extending equipment lifespan.

[0028] Optimize system efficiency: Combining pressure and weighing data can generate operation reports. By analyzing the correlation between pressure and belt load, conveying efficiency can be optimized; statistical analysis of correction frequency and pressure peaks allows for the development of reasonable equipment maintenance plans, improving the overall operating efficiency of the system.

[0029] It has predictive maintenance capabilities: by leveraging changes in pressure data, it can provide early warnings of potential faults, reduce the risk of abnormal downtime, and ensure the continuous and stable operation of the belt scale weighing system. Attached Figure Description

[0030] To more clearly illustrate the technical solution of the present invention, the drawings used in the embodiments are briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0031] Figure 1 This is a top view of a belt scale weighing system using a digital hydraulic automatic correction device, according to an embodiment of the present invention.

[0032] Figure 2 This is a schematic diagram of the installation of a belt scale weighing system using a digital hydraulic automatic correction device, according to an embodiment of the present invention.

[0033] Figure 3 This is another installation diagram of a belt scale weighing system using a digital hydraulic automatic correction device, according to an embodiment of the present invention. Detailed Implementation

[0034] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0035] To make the above-mentioned objects, features and advantages of the present invention more apparent and understandable, the present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments.

[0036] Example 1:

[0037] like Figure 3 As shown, this embodiment provides a belt scale weighing system using a digital hydraulic automatic belt alignment device. The device is installed outside the weighing area and automatically corrects belt misalignment, converting the direction and degree of belt deviation into corresponding pressure values. The device is connected to a fieldbus, and the instrument monitors the belt's off-center load in real time. Combining internal algorithms and data from other sensors, the instrument compensates for the off-center load within the weighing area. This system achieves dual protection through "physical correction + data correction." Figure 1 , Figure 2 As shown, each of the left and right drive wheels is equipped with a three-way connector, which is connected to the composite hydraulic cylinder and the digital pressure gauge respectively. The dynamic idler carries the belt and is fixed to the bracket via a rotating flange. The dynamic idler is connected to the composite hydraulic cylinder, and the rotation angle of the dynamic idler can be adjusted by the extension and retraction of the composite hydraulic cylinder driven by the oil pump.

[0038] Specifically, the front and rear ends of the belt scale are equipped with digital hydraulic automatic correction devices; the digital hydraulic automatic correction device includes: a detection drive wheel, an oil pump, a composite cylinder, a fixed frame, a fixed bracket, and a digital pressure gauge; the fixed frame is connected to the frame of the belt scale to provide stable support for the digital hydraulic automatic correction device; the fixed bracket is used to fix the detection drive wheel and the composite cylinder to ensure their stable position.

[0039] A further implementation involves the following: the drive pulley contacts the belt to detect belt misalignment; the drive pulley is connected to the oil pump to drive the pump; the oil pump is connected to the composite cylinder via an oil pipe to provide pressurized oil to the cylinder; the composite cylinder is connected to the dynamic idler to adjust its angle; the dynamic idler is fixed to the fixed frame via a rotatable flange to support and adjust the belt; a digital pressure gauge is connected to the composite cylinder to detect belt misalignment data; and the digital pressure gauge is connected to the belt scale's instrument via an RS485 bus for data transmission.

[0040] A further implementation involves the belt scale's instrument having a built-in off-center load compensation module. This module establishes a data connection with both the digital pressure gauge and the belt scale's load cell to receive pressure data and initial weighing data. It then performs off-center load compensation calculations based on a preset algorithm and outputs the compensated weighing data.

[0041] A further implementation involves activating the off-center load compensation module when the digital pressure gauge detects that the pressure deviation between the left and right sides of the composite cylinder exceeds the threshold and the belt misalignment is not corrected when passing through the weighing area.

[0042] The working principle of this invention is as follows: When the conveyor belt deviates from its designated position as it passes through the weighing area of ​​the belt scale, the detection and drive wheels in the digital hydraulic automatic deviation correction device located before and after the scale body will first detect the belt deviation and then drive the oil pump to start. After the oil pump starts, it provides pressurized oil, which enters the composite cylinder. Under the action of the hydraulic oil, the composite cylinder pushes or pulls the dynamic idler roller to rotate, applying an adjustment force to the belt and moving it to the correct position.

[0043] During the correction process, a digital pressure gauge monitors the pressure on both sides of the composite cylinder in real time. This pressure data not only indicates the current correction action and belt misalignment status, but is also transmitted to the belt scale's instrument via an RS485 bus. When the belt returns to its normal position under the adjustment action, the drive wheel stops driving the oil pump, the hydraulic device stops operating, and the pressure on both sides of the composite cylinder returns to zero.

[0044] When the digital pressure gauge detects a large pressure deviation between the left and right sides of the composite cylinder, and the belt misalignment is not corrected when passing through the weighing area, the off-center load compensation module of the belt scale instrument is activated. Based on the pressure deviation data, the off-center load compensation is performed on the initial weighing data to obtain an accurate weighing result.

[0045] A further implementation involves determining whether the left-right pressure deviation exceeds a threshold using the following method:

[0046] in,

[0047]

[0048] In the formula, T represents the time window; P L (t) represents the time series of pressure in the left hydraulic cylinder; P R (t) represents the time series of pressure in the right cylinder.

[0049] When the pressure deviation between the left and right sides exceeds a threshold, an anomaly is identified. Anomaly trends are used to detect situations where pressure changes are too rapid, typically indicating sudden changes or rapid fluctuations. These are signals of potential malfunctions in belt conveyor systems. By monitoring the rate of pressure change, abnormal trends can be identified, allowing for timely corrective action.

[0050] A further implementation involves the following method for calculating the compensated weighing data:

[0051] Wc=αP+βΔP+γWr+δ;

[0052] In the formula, Wc represents the weighing compensation result; α represents the degree of influence of the deviation pressure P on the weighing compensation; β represents the degree of influence of the pressure difference ΔP on the weighing compensation; γ represents the influence of the original weighing Wr on the compensation result; δ is a constant bias, representing the basic compensation value under the condition of no pressure or deviation.

[0053] Example 2:

[0054] This embodiment will describe the system's operation method in detail, taking into account the system structure in the above embodiments.

[0055] 1. System Installation:

[0056] The fixed frame is securely connected to the scale body frame of the belt scale to ensure the stability of the entire digital hydraulic automatic deviation correction device. Detection wheels are installed at the front and rear ends of the scale body, and the detection wheels and composite cylinders are fixed in appropriate positions using fixed brackets to ensure close contact between the detection wheels and the conveyor belt, enabling accurate detection of belt deviation.

[0057] The oil pump is installed near the composite cylinder, connected to it via an oil pipe with proper sealing to prevent hydraulic oil leakage. A digital pressure gauge is installed at the designated interface on the composite cylinder, ensuring accurate pressure detection on both sides. The off-center load compensation module of the belt scale is connected to the digital pressure gauge and load cell. Finally, the digital pressure gauge is connected to the belt scale's instrument via an RS485 bus, completing the system installation.

[0058] 2. Parameter settings:

[0059] A pressure threshold is set in the instrument of the belt scale. When the pressure detected by the digital pressure gauge exceeds this threshold, the instrument triggers an alarm. Simultaneously, a pressure deviation threshold P is set to determine whether off-center load compensation is needed. The conversion coefficient K between pressure deviation and off-center load, as well as the proportionality constant k related to the belt scale structure, are calibrated experimentally and input into the off-center load compensation module of the instrument. Relevant data transmission parameters are set to ensure that the pressure data detected by the digital pressure gauge can be accurately and in real-time transmitted to the instrument via the RS485 bus.

[0060] 3. Operational monitoring:

[0061] The instrument receives pressure data from the digital pressure gauge and initial weighing data from the load cell in real time, reflecting the operating status of the belt alignment device through the pressure data. When the pressure deviation exceeds P, the off-center load compensation module automatically starts, calculates the compensated weighing data according to the off-center load compensation formula, and displays it.

[0062] Operators can view information such as current correction actions, belt misalignment status, pressure change trends, and weighing data before and after compensation through the instruments. When the instruments trigger an alarm, operators can quickly locate and handle the problem based on the alarm information and correction records. Pressure data, initial weighing data, and weighing data after compensation are analyzed regularly to generate operation reports. Based on these reports, conveyor efficiency and equipment maintenance plans can be optimized. Simultaneously, the conversion factor K and proportional constant k can be recalibrated according to actual conditions to ensure the accuracy of off-center load compensation.

[0063] The embodiments described above are merely preferred embodiments of the present invention and are not intended to limit the scope of the present invention. Various modifications and improvements made to the technical solutions of the present invention by those skilled in the art without departing from the spirit of the present invention should fall within the protection scope defined by the claims of the present invention.

Claims

1. A belt scale weighing system using a digital hydraulic automatic deviation correction device, characterized in that, The front end and the rear end of the belt scale body are provided with digital hydraulic automatic deviation correction devices; the digital hydraulic automatic deviation correction device comprises a detection wheel, an oil pump, a composite oil cylinder, a dynamic roller, a fixed rack, a fixed support and a digital pressure gauge; The fixed rack is connected with the rack of the belt scale and provides support for the digital hydraulic automatic deviation correction device; the fixed support is used for fixing the detection wheel and the composite oil cylinder.

2. The belt scale weighing system with digital hydraulic automatic deviation correction device according to claim 1, characterized in that, The detection wheel is in contact with the belt and is used for detecting the deviation of the belt; The detection wheel is connected with the oil pump and is used for driving the oil pump to work; The oil pump is connected with the composite oil cylinder through an oil pipe and is used for providing pressure oil for the composite oil cylinder; The composite oil cylinder is connected with the dynamic roller and is used for adjusting the angle of the dynamic roller; The dynamic roller is fixed on the fixed rack through a rotatable flange and is used for supporting and adjusting the belt; The digital pressure gauge is connected with the composite oil cylinder and is used for detecting deviation data; The digital pressure gauge is connected with the instrument of the belt scale through an RS485 bus and is used for data transmission.

3. The belt scale weighing system with digital hydraulic automatic deviation correction device according to claim 2, characterized in that, The instrument of the belt scale is provided with an unbalanced load compensation module; The unbalanced load compensation module is connected with the digital pressure gauge and the weighing sensor of the belt scale and is used for receiving pressure data and initial weighing data and performing unbalanced load compensation calculation according to a preset algorithm and outputting compensated weighing data.

4. The belt scale weighing system with digital hydraulic automatic deviation correction device according to claim 3, characterized in that, When the digital pressure gauge monitors that the left-right pressure deviation of the composite oil cylinder exceeds a threshold value and the deviation of the belt is not corrected when passing through the weighing area, the unbalanced load compensation module is started.

5. The belt scale weighing system with digital hydraulic automatic deviation correction device according to claim 4, characterized in that, The judgment method that the left-right pressure deviation exceeds the threshold value is as follows: wherein In the formula, T represents a time window; P L (t) represents a left cylinder pressure time sequence; P R (t) represents a right cylinder pressure time sequence.

6. The belt scale weighing system with digital hydraulic automatic deviation correction device according to claim 3, characterized in that, The calculation method of the compensated weighing data comprises: Wc=αP+βΔP+γWr+δ; In the formula, Wc represents the weighing compensation result; α represents the influence degree of the deviation pressure P on the weighing compensation; β represents the influence degree of the pressure difference ΔP on the weighing compensation; γ represents the influence of the original weighing Wr on the compensation result; and δ is a constant bias, representing the basic compensation value in the case of no pressure or deviation.

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